Heat Controller Inc Air Conditioner BG 103A User Manual

HEAT CONTROLLER, INC.  
Through-The-Wall  
Air Conditioning  
Model: BG-103A  
Service Manual  
CAUTION  
-Before servicing the unit, read the "safety precautions" in this manual.  
-Only for authorized service personnel.  
1.3 SPECIFICATIONS  
1.3.1 FOR BG-103A  
Model  
BG-103A  
REMARK  
Items  
1Ø, 230/208V, 60Hz  
POWER SUPPLY  
10,500 / 10,000  
COOLING CAPACITY  
INPUT  
(Btu/h)  
1,230 / 1,170  
(W)  
5.7 / 6.0  
8.5 / 8.5  
RUNNING CURRENT  
E.E.R  
(A)  
(Btu/W.h)  
INDOOR(°C)  
OUTDOOR(°C)  
26.7(DB) 19.4(WB)  
OPERATING  
35(DB) 23.9(WB)  
TEMPERATURE  
475g(16.8OZ)  
REFRIGERANT (R-22) CHARGE (g)  
EVAPORATOR  
3ROW 12STACKS  
2ROW 17STACKS, L-BENDING TYPE  
TURBO FAN  
LOUVERED-FIN TYPE  
CONDENSER  
FAN, INDOOR  
PROPELLER TYPE FAN WITH SLINGER-RING  
3/3  
FAN, OUTDOOR  
FAN SPEED (FAN/COOLING/HEATING)  
FAN MOTOR  
4POLES  
ELECTRIC  
OPERATION CONTROL  
ROOM TEMP. CONTROL  
AIR DIRECTION CONTROL  
THERMISTOR  
VERTICAL LOUVER(RIGHT & LEFT)  
HORIZONTAL(UP & DOWN)  
TOP-DOWN  
CONSTRUCTION  
EXTERNAL OVERLOAD PROTECTOR  
INTERNAL THERMAL PROTECTOR  
1.4m (3WIRES WITH GROUNDING)  
ATTACHMENT PLUG(CORD-CONNECTED TYPE, LCDI)  
SPLASHED BY FAN SLINGER  
80/36  
PROTECTOR  
COMPRESSOR  
FAN MOTOR  
POWER CORD  
DRAIN SYSTEM  
NET WEIGHT  
(lbs/kg)  
(inch)  
(mm)  
(inch)  
(mm)  
(inch)  
(mm)  
24 x 14 13/32 x 20 3/32  
DIMENSION  
610 x 366 x 499  
(W x H x D)  
25 7/8 x 15 17/32 x 16 23/32  
656 x 394 x 425  
SLEEVE DIMENSION  
(W x H x D)  
SLEEVE DEPTH  
WITH FRONT GRILLE  
20 1/2  
521  
—3—  
1.4 FEATURES  
• Designed for cooling only.  
• Side air-intake, side cooled-air discharge.  
• Built in adjustable THERMISTOR and THERMOSTAT.  
• Washable one-touch filter.  
• Powerful and quiet cooling.  
• Top-down chassis for the simple installation and service.  
• Compact size.  
1.5 CONTROL LOCATIONS  
1.5.1 COOLING ONLY MODEL  
• OPERATION  
FAN SPEED  
Every time you push this button, it advances the setting as follows: {High ¡ Low ¡ Med ¡ High}  
REMOTE CONTROL SIGNAL RECEIVER  
'
Cool  
F
F1 LOW  
F2 MED  
F3 HIGH  
TEMPERATURE SETTING  
Energy  
Saver  
Use this button to automatically control the temperature of the room.  
The temperature can be set within a range of 60°F to 86°F by increments of  
1°F.  
Fan  
TEMP  
Timer  
The setting appears in the display.  
FAN  
MODE  
TIMER  
POWER  
POWER  
SPEED  
To turn the air conditioner ON, push this button.  
To turn the air conditioner OFF, push the button again.  
This button takes priority over any other button.  
When you first turn it on, the unit is in cool mode, High fan speed,  
Temperature setting at 72°F.  
TIMER  
- SHUT-OFF TIME  
You will usually use shut-off time while you sleep.  
If unit is running, use Timer to set number of hours until shut-off.  
For your sleeping comfort, once Time is set, the Temperature setting will raise 2°F after 30 min., and once again after another 30 min.  
Push Timer button to advance setting from 1Hour ¡ 2Hours ¡ ... ¡ 12Hours maximum.  
- START TIME  
If unit is off, use Timer to set number of hours before unit starts.  
Push Timer button to advance setting from 1Hour ¡ 2Hours ¡ ... ¡ 12Hours maximum.  
MODE  
-
Push this button to shift mode of operation from COOL ¡ ENERGY SAVER ¡ FAN.  
- COOL:  
Fan runs continually for normal cooling operation.  
- ENERGY SAVER:  
The fan stops when the compressor stops cooling. Approximately every 3 minutes the fan will turn on and the unit will check the room air  
temperature to determine if cooling is needed.  
- FAN:  
Fan-only operation.  
• VENTILATION  
Push the lever to the "CLOSE" position to cool, heat or recirculate room air only.  
Pull the lever to the "OPEN" position to exhaust smoke or stale air from the room.  
This feature is best used in conjunction with the FAN ONLY position.  
CAUTION  
When the air conditioner has been operating in the  
cooling and is turned off or set to the fan only position,  
wait at least 3 minutes before resetting to the cooling  
operation again.  
PULL OPEN / PUSH CLOSE  
4—  
2. DISASSEMBLY INSTRUCTIONS  
Prior to disassembling the unit, make sure that the POWER is off and the power cord is unplugged from the  
wall receptacle.  
2.1 MECHANICAL PARTS  
'
F
W
LO  
D
F1 ME  
F3  
F
2
H
I
G
ool  
EMP  
N
R
E
C
T
y
W
O
P
n
e
rg  
e
r
E
a
v
S
er  
Tim  
n
A
PEE  
Fa  
F
S
D
R
E
M
TI  
E
D
O
M
2.1.1 FRONT GRILLE  
1. Open the inlet grille downward.  
2. Remove the screw which fastens the front grille.  
3. Pull the front grille from the right side.  
4. Remove the front grille. (See Fig. 1)  
5. Re-install the component by referring to the  
removal procedure.  
Cool  
F
1
L
O
W
'
F
F2 MED  
F3 HIGH  
Energy  
Saver  
Fan  
TEMP  
Timer  
F
AN  
MODE  
TIMER  
POWER  
SPEED  
Figure 1  
2.1.2 CABINET  
1. After disassembling the FRONT GRILLE, remove  
the 6 screws which fasten the cabinet at the both  
sides and the top. (See Fig. 2)  
Keep these for later use.  
C
o
o
l
E
S
n
er  
g
y
av  
er  
F
a
n
F1  
LO  
F2  
W
ME  
F3  
D
H
IG  
H
T
im  
e
'
r
F
M
O
D
TEMP  
E
T
IM  
E
R
F
A
SPEED  
N
P
O
W
E
R
Figure 2  
2.1.3 CONTROL BOX  
1. Remove the front grille. (Refer to section 2.1.1)  
2. Remove the screw which fasten the control  
box. (See Fig. 3)  
C
o
o
l
Ener  
Sa  
gy  
ver  
F
a
n
F
1
M
L
F
O
W
2
F
E
D
3
H
IG  
H
T
im  
e
'
r
F
MODE  
T
E
M
P
TIMER  
F
E
A
S
N
P
E
3. Pull the control box from the barrier.(See Fig.3)  
4. Discharge the capacitor by placing a 20,000 ohm  
resistor across the capacitor terminals.  
5. Disconnect two wire housings in the control box.  
6. Pull the control box forward completely.  
7. Re-install the components by referring to the  
removal procedure. (See Fig. 3)  
WER  
Figure 3  
(Refer to the circuit diagram found on pages 25 in  
this manual and on the control box.)  
5—  
2.2 AIR HANDLING PARTS  
2.2.1 ORIFICE, AND TURBO FAN  
1. Remove the front grille. (Refer to section 2.1.1)  
2. Remove the cabinet. (Refer to section 2.1.2)  
3. Remove the 2 screws which fasten the  
evaporator at the left side and the right side.  
(See Fig. 4)  
Cool  
E
S
ne  
rg  
y
av  
er  
Fa  
n
F1  
LO  
F2  
W
M
F3  
ED  
H
IG  
H
Time  
r
'
F
M
O
D
T
E
E
M
P
TI  
M
E
R
F
E
A
S
N
P
E
D
P
O
W
E
R
4. Move the evaporator sideward carefully.  
Figure 4  
5. Remove the orifice. (See Fig. 5)  
C
o
o
l
E
S
ne  
rg  
y
av  
er  
an  
F
F1  
LO  
F2  
W
M
F3  
ED  
HIG  
H
T
im  
er  
'
F
M
O
D
T
EMP  
E
T
IM  
E
R
F
E
A
S
N
P
E
D
P
O
W
E
R
Figure 5  
8. Using handheld pliers, remove the clamp which  
secures the turbo fan. (See Fig. 6)  
C
o
o
l
E
S
ne  
rg  
y
av  
er  
an  
F
F1  
F3 ME  
HIG  
F
2
L
O
W
D
H
T
im  
er  
'
F
M
O
D
T
E
EM  
P
T
IM  
E
R
F
E
A
E
S
N
P
D
P
O
W
E
R
Figure 6  
9. Remove the turbo fan with pliers or your hand,  
without touching blades. (See Fig. 7)  
10. Re-install the components by referring to the  
removal procedures, above.  
C
o
o
l
E
S
ne  
rg  
y
av  
er  
an  
F
F1  
F
2
L
O
W
F
3
M
E
D
HIG  
H
T
im  
er  
'
F
M
O
D
TEM  
N
E
P
T
IM  
E
R
F
E
A
E
S
P
D
P
O
W
E
R
Figure 7  
2.2.2 FAN  
1. Remove the cabinet. (Refer to section 2.1.2)  
2. Remove the brace.  
(Refer to section 2.2.1)  
3. Remove the 7 screws which fasten the condenser.  
4. Move the condenser sideways carefully.  
5. Using handheld pliers, remove the clamp which  
secures the fan.  
6. Remove the fan. (See Fig. 8)  
7. Re-install the components by referring to the  
removal procedures, above.  
Figure 8  
6—  
2.2.3 SHROUD  
1. Remove the fan. (Refer to section 2.2.2)  
2. Remove the shroud. (See Fig. 9)  
3. Re-install the components by referring to the  
removal procedures, above.  
2.3 ELECTRICAL PARTS  
2.3.1 MOTOR  
1. Remove the cabinet. (Refer to section 2.1.2)  
2. Remove the clamp cord and disconnect the wire  
housing in control box. (Refer to section 2.1.3)  
3. Remove the turbo fan. (Refer to section 2.2.2)  
4. Remove the fan. (Refer to section 2.2.2)  
5. Remove the 4 or 2 screws which fasten the motor.  
(See Fig. 10)  
Figure 9  
6. Remove the motor.  
7. Re-install the components by referring to the  
removal procedures, above.  
2.3.2 COMPRESSOR  
1. Remove the cabinet. (Refer to section 2.1.2)  
2. Discharge the refrigerant system using a FreonTM  
Recovery System.  
Figure 10  
If there is no valve to attach the recovery system  
to, install one (such as a WATCO A-1) before  
venting the FreonTM . Leave the valve in place after  
servicing the system.  
3. Disconnect the 3 leads from the compressor.  
4. After purging the unit completely, unbraze the  
suction and discharge tubes at the compressor  
connections.  
5. Remove the 3 nuts and the 3 washers which  
fasten the compressor. (See Fig. 11)  
6. Remove the compressor.  
7. Re-install the components by referring to the  
removal procedures, above.  
Figure 11  
2.3.3 CAPACITOR  
1. Remove the control box. (Refer to section 2.1.3)  
2. Remove the 1 screw  
3. Open the control box  
4. Disconnect all the leads on the capacitor terminals.  
5. Re-install the components by referring to the  
removal procedures, above.  
C
o
o
l
E
S
n
a
e
v
rg  
e
y
r
F
a
n
F1 LO  
W
F2 MED  
F3 HIGH  
T
i
m
e
'
r
F
M
O
DE  
TE  
M
P
TIM  
ER  
FA  
SPEE  
N
D
P
O
W
E
R
Figure 12  
7—  
2.3.4 POWER CORD  
1. Remove the control box. (Refer to section 2.1.3)  
2. Unfold the control box. (Refer to section 2.3.3)  
3. Disconnect the grounding screw from the Base  
pan.  
4. Disconnect 2 receptacles.  
5. Remove a screw which fastens the clip cord.  
6. Pull the power cord. (See Fig. 13)  
7. Re-install the components by referring to the  
removal procedure, above.  
(Use only one ground-marked hole, , for ground  
connection.)  
8. If the supply cord of this appliance is damaged, it  
must be replaced with the factory-authorized and  
specified cord.  
Figure 13  
C
ool  
Ener  
Sa  
gy  
ver  
Fa  
n
F1 LO  
F2 MED  
F3 HIGH  
W
2.3.5 THERMISTOR  
Tim  
er  
'
F
MODE  
TEMP  
TIMER  
1. Remove the control box. (Refer to section 2.1.3)  
2. Unfold the control box. (Refer to section 2.3.3)  
3. Disconnect all the leads of thermistor terminals.  
4. Remove the thermistor. (See Fig. 14)  
5. Re-install the components by referring to the  
removal procedures, above.  
FA  
N
SPEED  
PO  
WER  
Figure 14  
8—  
2.4 REFRIGERATION CYCLE  
CAUTION  
TM  
Discharge the refrigerant system using a Freon  
Recovery System.  
If there is no valve to attach the recovery system,  
install one (such as a WATCO A-1) before  
TM  
venting the Freon . Leave the valve in place  
after servicing the system.  
2.4.1 CONDENSER  
1. Remove the cabinet. (Refer to section 2.1.2)  
2. Remove the brace.  
(Refer to section 2.2.1)  
3. Remove the 7 screws which fasten the condenser.  
4. After discharging the refrigerant completely into a  
FreonTM Recovery System, unbraze the  
interconnecting tube at the condenser  
connections.  
5. Remove the condenser.  
6. Re-install the components by referring to the notes  
(See Fig. 15)  
Figure 15  
2.4.2 EVAPORATOR  
1. Remove the cabinet. (Refer to section 2.1.2)  
2. Discharge the refrigerant completely into a  
FreonTM Recovery System.  
3. Remove the 2 screws which fasten the evaporator  
at the left side and the right side.  
4. Move the evaporator sideward carefully and then  
unbraze the interconnecting tube at the evaporator  
connectors.  
C
o
o
l
E
S
n
a
e
v
rg  
y
e
r
F
a
n
F1  
LO  
W
F
2
M
E
F3  
D
HIGH  
T
im  
e
'
r
F
M
O
D
E
TEMP  
N
T
IM  
E
R
F
EED  
A
SP  
P
O
W
E
R
5. Remove the evaporator.  
6. Re-install the components by referring to the notes  
(See Fig. 16)  
Figure 16  
2.4.3 CAPILLARY TUBE  
1. Remove the cabinet. (Refer to section 2.1.2)  
2. After discharging the refrigerant completely into  
a FreonTM Recovery System, unbraze the  
interconnecting tube at the capillary tube.  
3. Remove the capillary tube.  
4. Re-install the components by referring to the notes.  
9—  
NOTES  
Replacement of the refrigeration cycle.  
1. When replacing the refrigeration cycle, be sure to  
discharge the refrigerant system using a FreonTM  
recovery System.  
6. Recharge as follows :  
1) Refrigeration cycle systems are charged from the  
High-side. If the total charge cannot be put  
in the High-side, the balance will be put in the  
suction line through the access valve which you  
installed as the system was opened.  
2) Connect the charging cylinder as shown in Fig. 17B.  
With valve C open, discharge the hose at the  
manifold connection.  
3) Open valve A and allow the proper charge to  
enter the system. Valve B is still closed.  
4) If more charge is required, the high-side will not  
take it. Close valve A.  
5) With the unit running, open valve B and add the  
balance of the charge.  
a. Do not add the liquid refrigerant to the Low-  
side.  
b. Watch the Low-side gauge; allow pressure to  
rise to 30 lbs.  
c. Turn off valve B and allow pressure to drop.  
d. Repeat steps B and C until the balance of the  
charge is in the system.  
If there is no valve to attach the recovery system,  
install one (such as a WATCO A-1) before venting  
the FreonTM. Leave the valve in place after  
servicing the system.  
2. After discharging the unit completely, remove the  
desired component, and unbrace the pinch-off  
tubes.  
3. Solder service valves into the pinch-off tube ports,  
leaving the valves open.  
4. Solder the pinch-off tubes with Service valves.  
5. Evacuate as follows.  
1) Connect the vacuum pump, as illustrated Fig.  
17A.  
2) Start the vacuum pump, slowly open manifold  
valves A and B with two full turns  
counterclockwise and leave the valves closed.  
The vacuum pump is now pulling through valves  
A and B up to valve C by means of the manifold  
and entire system.  
6) When satisfied the unit is operating correctly,  
use the pinch-off tool with the unit still running  
and clamp on to the pinch-off tube. Using a tube  
cutter, cut the pinch-off tube about 2 inches from  
the pinch-off tool. Use sil-fos solder and solder  
pinch-off tube closed. Turn off the unit, allow it to  
set for a while, and then test the leakage of the  
pinch-off connection.  
CAUTION  
If high vacuum equipment is used, just crack  
valves A and B for a few minutes, then open  
slowly with the two full turns counterclockwise.  
This will keep oil from foaming and being  
drawn into the vacuum pump.  
3) Operate the vacuum pump for 20 to 30 minutes,  
until 600 microns of vacuum is obtained. Close  
valves A and B, and observe vacuum gauge for  
a few minutes. A rise in pressure would  
indicate a possible leak or moisture remaining in  
the system. With valves A and B closed, stop  
the vacuum pump.  
4) Remove the hose from the vacuum pump and  
place it on the charging cylinder. See Fig. 17B.  
Open valve C.  
Discharge the line at the manifold connection.  
5) The system is now ready for final charging.  
10—  
Equipment needed: Vacuum pump, Charging cylinder, Manifold gauge, Brazing equipment. Pinch-off tool  
capable of making a vapor-proof seal, Leak detector, Tubing cutter, Hand Tools to remove components, Service  
valve.  
COMPOUND GAUGE  
CONDENSER  
(HIGH PRESSURE SIDE)  
MANIFOLD  
GAUGE  
A
B
CAPILLARY TUBE  
SEE INSETS  
BELOW  
EVAPORATOR  
(LOW PRESSURE SIDE)  
COMPRESSOR  
HI  
LOW  
A
B
A
B
EXTERNAL  
VACUUM PUMP  
CHARGING  
CYLINDER  
C
Figure 17A-Pulling Vacuum  
Figure 17B-Charging  
11—  
3. INSTALLATION  
3.1 INSTALLATION REQUIREMENTS  
INSTALLATION HARDWARE  
If you use an existing wall sleeve, you should measure its  
dimensions.  
2
4
1
5
Install the new air conditioner according to these installation  
instructions to achieve the best performance. All wall sleeves  
used to mount the new air conditioner must be in good  
structural condition and have a compatible rear grille in order  
to securely attach the new air conditioner. (FIG. 18A)  
With the FRIEDRICH USC sleeve, you can maintain the  
best performance of the new air conditioner. (FIG. 18B)  
2 Size options  
6
8
3
9
7
2 Size options  
20-3/32"  
(511 mm)  
24"(610 mm)  
ITEM  
NAME OF PARTS  
PLASTIC GRILLE  
VERTICAL INSULATION STRIP  
AROUND INSULATION STRIPS  
HORIZONTAL INSULATION STRIP  
SUPPORT BLOCK  
BAFFLE  
TRIM FRAME  
SHIM  
Q'TY  
1
1
2
1
2
1
2
2
4
14-13/32"  
(366 mm)  
18-15/32"(468 mm)  
Air Conditioner  
FIG. 18A  
PLASTIC NUTS AND WASHER SCREWS  
25-7/8"  
(656 mm)  
CAUTION  
To avoid risk of personal injury, property damage, or  
product damage due to the weight of this device and sharp  
edges that may be exposed:  
15-17/32"  
(394 mm)  
Air conditioners covered in this manual pose an  
excessive weight hazard. Two or more people are  
aluminum metal grille  
16-23/32"  
(425 mm)  
needed  
to  
move  
and  
install  
the  
unit.  
To prevent injury or strain, use proper lifting and carrying  
techniques when moving unit.  
FRIEDRICH USC Wall Sleeve  
FIG. 18B  
Carefully inspect location where air conditioner will be  
installed. Be sure it will support the weight of the unit  
over an extended period of time.  
ELECTRICAL SERVICE  
Handle air conditioner with care. Wear protective gloves  
whenever lifting or carrying the unit. AVOID the sharp  
metal fins of front and rear coils.  
Check your available electrical service. The power supply  
available must be the same as that shown on the unit  
nameplate (found on left side of cabinet).  
Make sure air conditioner does not fall during installation.  
All models are equipped with a 3-prong service plug to  
provide proper service and safe positive grounding. Do not  
change plug in any way. Do not use an adapter plug. If your  
present wall outlet does not match your plug, call a qualified  
electrician to make the necessary corrections. SAVE  
CARTON for storage and this OWNER'S MANUAL for future  
reference. The carton is the best way to store unit during  
winter or when not in use.  
REQUIRED TOOLS:  
3/8-inch open end  
wrench or adjustable  
wrench  
1/4-inch hex socket  
and ratchet  
Tape measure  
Electric drill  
Tight Fitting gloves  
Standard screwdriver  
Phillips screwdriver  
Pliers  
Sharp knife  
1/4-inch drill bit  
12—  
NOTE: All wall sleeves used to mount the new Air  
Conditioner must be in sound structural condition and have a  
rear grille that securely attaches to sleeve, or rear flange that  
serves as a stop for the Air Conditioner.  
3.2 INSTALLATION  
CAUTION  
Installing the FRIEDRICH USC sleeve ensures  
optional performances of the unit.  
Remove old air conditioner from existing wall sleeve.  
2
If you decide to keep the existing wall sleeve, you have  
to redirect the louvers at the back of the wall sleeve.  
Refer to FIG. 23 on p15. The use of pliers is  
recommended. If you DO NOT redirect, you run the risk  
of poor performance or premature product failure. This  
is not covered under the terms of the FRIEDRICH  
warranty.  
Clean the interior of an existing sleeve.  
(Do not disturb seals.)  
3
Wall sleeve must be securely fastened in wall before  
installing the air conditioner. Use the nails or screws  
through sleeve into wall, if needed. Repaint sleeve if  
needed.  
4
Prepare the wall sleeve for installation of the unit. If you  
plan to use your existing wall sleeve, and it is not  
FRIEDRICH, use procedure B or C below.  
Pick a location which will allow the conditioned air to blow  
into the area you want. Good installation with special  
attention to the proper position of the unit will lessen the  
chance that service will be needed.  
5
Procedure  
Brand  
Depth(inches)  
A(page 16)  
FRIEDRICH USC  
White-Westinghouse  
Frigidaire Carrier  
(52F series)  
General Electric  
/Hotpoint  
16-23/32  
ITEMS IN INSTALLATION HARDWARE  
You may not need all parts in the kit. Discard unused parts  
16, 17-1/2  
or 22  
ITEM (inches)  
Qty.  
1
1
1
1
1
2
1
2
B
Plastic grille  
263/ x 161/  
2
4
(pages 17~18)  
16-7/8  
Vertical insulation strip  
159/16 x 13/ x 13/  
8
8
671/ x 13/ x 25  
/
8
8
32  
Whirlpool  
17-1/8 or 23  
Around Insulation Strips  
5927/32 x 13/ x 13/  
8
8
Carrier (51S series)  
Fedders/Emerson  
Friedrich WSC  
Emerson/Fedders  
18-5/8  
16-3/4  
or 19-3/4  
15  
Horizontal Insulation Strip  
Support Block  
Baffle  
237/32 x 13/ x 13/16  
8
C
13/ x 13/ x 45/  
4
8
16  
(pages 19)  
14 x 41/2 x 1/  
8
Shim  
1113  
/
16 x 1 x 3  
/
4
Trim Frame  
Washer Screw  
Nuts(Plastic)  
Grille Rear  
2
4
4
1
Install new unit into wall sleeve.  
6
CAUTION: When installation is completed, replacement unit  
MUST have a rearward slope as shown. To achieve 1/4"  
slope, remove the backing from the 11-13/16" shim strips and  
attach them as shown below in Fig. 19. Place the higher  
portion of shim to the front of the rib on base of wall sleeve.  
HOW TO INSTALL  
Before installing the unit, identify the existing wall sleeve  
from the list below.  
1
Wall Sleeve Dimensions (inches)  
Brand  
1" high  
3
/ " High  
4
Width  
Height  
Depth  
White-Westinghouse  
Frigidaire  
Carrier (52F series)  
General Electric  
/Hotpoint  
UNIT  
Wall Sleeve  
16, 17-1/2  
or 22  
25-1/2  
15-1/4  
26  
25-7/8  
27  
15-5/8  
16-1/2  
16-3/4  
16-7/8  
FRONT  
1/4"  
Shim  
17-1/8  
or 23  
16-3/4  
or 19-3/4  
16-23/32  
15  
Whirlpool  
Fedders/Emerson  
Friedrich WSC  
FRIEDRICH USC  
Emerson/Fedders  
Carrier (51S Series)  
6"  
6"  
SHIM PLACEMENT  
UNIT INSTALLATION  
25-7/8  
26-3/4  
25-3/4  
15-17/32  
15-3/4  
16-7/8  
FIG. 19  
18-5/8  
13—  
PROCEDURE A  
Install the new unit into the wall sleeve.  
If you are using the new sleeve (optionally  
4
5
1
supplied with your unit),skip to step 3.  
Toassembletrim,tpthetabofeachpiece  
Otherwise, install the plastic grille from the kit.  
Cut the plastic grille to 25-1/2" wide and  
15-1/4" high. Place the plastic grille to the  
inside of the wall sleeve at the rear flange.  
into the slot of the other piece as shown below.  
Slide trim over the front of the air conditioner  
until trim is flush with sleeve as shown below.  
FIG.20  
Fasten the 4 washer screws to secure the grille  
to the wall sleeve. If you need plastic nuts to  
Trim (2 ea)  
2
mount plastic grille to the inside of the wall  
sleeve, there are plastic nuts in the installation  
kit. The nuts are installed from the inside of the  
sleeve and are pressing into the square holes  
of the rear flanges.Fasten the bracket to the  
upside of the wall sleeve using the washer  
screw. The bracket prevents the unit from  
leaving the sleeve.  
Wall  
Bracket  
Bracket  
FIG.23  
or  
Fasten the screws and the bracket  
FIG.21  
CAUTION  
Remove the backing from the Vertical  
Air conditioners covered in this manual pose an  
excessive weight hazard. Two or more people are  
needed to move and install the unit.  
To prevent injury or strain, use proper lifting and  
carrying techniques when moving unit.  
When handling the air conditioner, be careful to avoid  
cuts from sharp metal fins on front and rear coils.  
3
Insulation strip 159/16 x 13/ x 13/ and attach that  
8
8
to the inside right of the sleeve as shown  
below. Remove the backing from the Around  
Insulation strip 671/ x 13/ x 25/32 and attach that  
8
8
to the inside front of the sleeve as shown  
below.  
Indoor  
Outdoor  
Make sure air conditioner does not fall during  
removal.  
If unit does not operate after installation check, to be  
sure the circuit interrupter has not been tripped. Refer  
to the Troubleshooting guide for reset procedure.  
9 1/2"  
6"  
FIG. 22  
14—  
Remove the backing from the Vertical Insulation  
strip 159/16 x 13/8 x 13/8 and attach that to the  
inside right of the sleeve as shown below.  
Remove the backing from the Around Insulation  
strip 671/8 x 13/8 x 25/32 and attach that to the  
inside front of the sleeve as shown below.  
PROCEDURE B  
4
Redirect the louvers at the back of the wall  
1
sleeve to 60° angle as shown in the FIG 24. The  
use of pliers is recommended.  
7 3/  
"
32  
Indoor  
Outdoor  
60°  
60°  
Rear Louvers  
(Top View)  
9 1/2"  
6"  
FIG.24  
FIG. 27  
If the wall sleeve already has a rear grille, skip  
to step 4. If the wall sleeve does not have a rear  
grille or louvered panel, install the plastic grille  
from the kit. Cut the plastic grille to 25-1/2" wide  
and 15-1/4" high. Place the plastic grille to the  
inside of the wall sleeve at the rear flange.  
If the depth of your existing wall sleeve is less  
than or equal to 18", skip to step 7. Otherwise,  
2
5
cut the baffles and the support blocks according  
to length "A" in the table below.  
A
Length "A"  
(inches)  
Depth"D" of the existing  
wall sleeve (inches)  
Support  
Block  
3/4  
1-3/4  
4
18  
D
18-5/8  
19-3/4  
22  
18-5/8  
D
Baffle  
19-3/4  
D
A
FIG. 28  
Place the plastic grille  
FIG.25  
Fasten the 4 washer screws to secure the grille  
to the wall sleeve. If you need plastic nuts to  
mount plastic grille to the inside of the wall  
sleeve, there are plastic nuts in the installation  
kit. The nuts are installed from the inside of the  
sleeve and are pressed into the square holes of  
the rear flanges.Fasten the bracket to the  
upside of the wall sleeve using the washer  
screw. The bracket prevents the unit from  
leaving the sleeve.  
3
Bracket  
Bracket  
or  
FIG. 26  
Fasten the screws and the bracket  
15—  
PROCEDURE B CONTINUED  
Remove the backing from the support blocks and attach  
them to the inside of the wall sleeve as shown FIG 29.  
Slide the baffle into slots of the support blocks.  
6
(
7 3  
/
")  
32  
Wall  
Wall  
Sleeve  
Baffle  
Front  
Support  
Block  
FIG. 29  
Install the new unit into the wall sleeve.  
7
8
Assemble trim as described in Step 6,  
Procedure A.  
CAUTION  
Air conditioners covered in this manual pose an  
excessive weight hazard. Two or more people are  
needed to move and install the unit.  
To prevent injury or strain, use proper lifting and carrying  
techniques when moving unit.  
When handling the air conditioner, be careful to avoid  
cuts from sharp metal fins on front and rear coils.  
Make sure air conditioner does not fall during removal.  
If unit does not operate after installation check, to be sure  
the circuit interrupter has not been tripped. Refer to the  
Troubleshooting guide for reset procedure.  
16—  
Remove the backing from the Horizontal Insulation strip  
237/32 x 13/8 x 13/16 and attach that to the inside right of the  
sleeve as shown below. Remove the backing from the  
Around Insulation strip 5927/32 x 13/8 x 13/8 and attach that  
to the inside front of the sleeve as shown below.  
3.5 PROCEDURE C  
4
Redirect the louvers at the back of the wall sleeve to 60°  
angle as shown in the FIG 30. The use of pliers is  
1
recommended.  
7 13  
/
"
16  
Indoor  
Outdoor  
60°  
60°  
Rear Louvers  
Around Insulation  
Horizontal Insulation  
(Top View)  
8 1/2"  
FIG. 30  
FIG. 33  
If the wall sleeve already has a rear grille, skip to step 4. If the  
wall sleeve does not have a rear grille or louvered panel, install  
the plastic grille from the kit. Cut the plastic grille to 26-1/2"  
wide and 15-1/2" high or to the sleeve dimensions. Place the  
plastic grille to the inside of the wall sleeve at the rear flange.  
2
If the depth of your existing sleeve is less than or equal  
to 18, skip to step 7. Otherwise, cut the baffles and the  
support blocks according to Length "A" in the table  
below.  
5
A
Length "A"  
(inches)  
Depth"D" of the existing  
wall sleeve (inches)  
Support  
Block  
18-5/8  
3/4  
1-3/4  
4
18  
D
18-5/8  
D
19-3/4  
Baffle  
19-3/4  
D
22  
A
FIG. 34  
Remove the backing from the support blocks and attach  
them to the inside of the wall sleeve as shown FIG 35.  
Slide the baffle into slots of the support blocks  
FIG. 31  
Place the plastic grille  
6
Fasten the 4 washer screws to secure the grille to the  
wall sleeve. If you need plastic nuts to mount plastic grille  
to the inside of the wall sleeve, there are plastic nuts in  
the installation kit. The nuts are installed from the inside  
of the sleeve and are pressed into the square holes of  
the rear flanges. Fasten the bracket to the upside of the  
wall sleeve using the washer screw. The bracket  
prevents the unit from leaving the sleeve.  
3
(7 3/32")  
Wall  
Baffle  
Wall  
Sleeve  
Front  
Support  
Block  
Bracket  
Bracket  
FIG. 35  
or  
FIG. 32  
Fasten the screws and the bracket  
17—  
PROCEDURE C CONTINUED  
CAUTION  
To achieve rearward slope for unit draining,  
remove the backing from the 1113/16" shim  
7
Air conditioners covered in this manual pose an  
excessive weight hazard. Two or more people are  
needed to move and install the unit.  
To prevent injury or strain, use proper lifting and  
carrying techniques when moving unit.  
strips and attach them as shown below in Fig.  
37. The higher portion of shim is to be placed  
in front of the rib on the base of wall sleeve.  
When handling the air conditioner, be careful to avoid  
cuts from sharp metal fins on front and rear coils.  
1" high  
3/4" High  
Make sure air conditioner does not fall during  
removal.  
FIG. 36  
If unit does not operate after installation check, to be  
sure the circuit interrupter has not been tripped. Refer  
to the Troubleshooting guide for reset procedure.  
Shim (2EA)  
6"  
6"  
FIG. 37  
Install the new unit into the wall sleeve  
8
Assemble trim as described in Step 6,  
Procedure A.  
9
18—  
4. TROUBLESHOOTING GUIDE  
4.1 OUTSIDE DIMENSIONS  
20-3/32"  
24"  
(610mm)  
(499mm)  
Cool  
'
F
F1 LOW  
F2 MED  
F3 HIGH  
Energy  
Saver  
Fan  
TEMP  
Timer  
FAN  
MODE  
TIMER  
POWER  
SPEED  
4.2 PIPING SYSTEM  
CONDENSER COILS  
FAN  
CAPILLARY TUBE  
COMPRESSOR  
MOTOR  
TURBO FAN  
EVAPORATOR COILS  
: REFRIGERANT FLOW  
Following is a brief description of the important components and their functions in the refrigeration system.  
Refer to Fig. 41 to follow the refrigeration cycle and the flow of the refrigerant in the cooling cycle.  
ROOM AIR CONDITIONER  
CYCLE OF REFRIGERATION  
EVAPORATOR COILS  
CONDENSER COILS  
VAPOR INLET  
SUCTION LIME  
COOL LOW PRESSURE VAPOR  
HOT  
DISCHARGED  
AIR  
COMPLETE LIQUID  
BOIL OFF POINT  
COOLED  
AIR  
ROOM AIR HEAT LOAD  
OUTSIDE COOLING  
AIR FOR REFRIGERANT  
PASS THROUGH  
MOTOR  
COMPRESSOR  
OIL  
LIQUID  
PRESSURE  
DROP  
LIQUID OUTLET  
HIGH PRESSURE VAPOR  
(LIQUID REFRIGERANT)  
LIQUID PEFRIGERANT  
CAPILLARY TUBE  
LOW PRESSURE VAPOR  
Figure 41  
19—  
4.3 TROUBLESHOOTING GUIDE  
In general, possible trouble is classified in two causes.  
The one is called Starting Failure which is caused from an electrical defect, and the other is Ineffective Air  
Conditioning caused by a defect in the refrigeration circuit and improper application.  
Unit is running but cooling is ineffective  
Ineffective Cooling  
Check cold air circulation  
for smooth flow.  
Check outdoor coil  
(heat exchanger) & the fan  
operation.  
Check heat load increase.  
Unexpected residue  
Overloaded Circuit  
Dirty indoor coil  
(Heat exchanger)  
Check gas leakage.  
Repair gas leak.  
Malfunction of fan  
Clogged air filter  
Check inside gas pressure.  
Replacement of unit if the  
unit is beyond repair.  
Obstruction at air outlet  
Adjusting of refrigerant  
charge  
Stop auto air-swing  
Malfunction of compressor  
Correct above troubles  
Replacement of  
compressor  
Check clogging in  
refrigeration circuit.  
Satisfactory operation with  
temperature difference of  
inlet & outlet air ; 44.6~50˚F  
Repair clogging in  
refrigeration circuit.  
20—  
Fails to Start  
Check power source.  
Check circuit breaker  
and fuse.  
Check control switch  
setting.  
Gas leakage at feeler bulb  
of thermostat  
Check control switch.  
Only compressor fails to  
start.  
Only fan fails to start.  
Improper wiring.  
Drop in power voltage.  
Improper thermostat setting  
Defect of fan motor  
capacitor.  
Defective compressor  
capacitor.  
Loose terminal connection.  
Improper wiring  
Irregular motor resistance  
(
).  
Irregular motor insulation  
).  
Check capacitor.  
Replacement.  
(
Replacement of fan motor  
Regular but fails to start  
Irregular motor resistance ( )  
Irregular motor insulation ( )  
Replacement of compressor  
(locking of rotor, metal)  
Replacement of compressor  
(Motor damaged)  
21—  
COMPLAINT  
CAUSE  
REMEDY  
Fan motor will not run.  
No power  
Check voltage at outlet. Correct if none.  
Power supply cord  
Rotary switch  
Check voltage to rotary switch. If none, check  
power supply cord. Replace cord if circuit is open.  
Check switch continuity. Refer to wiring diagram  
for terminal identification. Replace switch if  
defective.  
Wire disconnected or  
connection loose  
Connect wire. Refer to wiring diagram for terminal  
identification. Repair or replace loose terminal.  
Capacitor (Discharge  
Test capacitor.  
capacitor before testing.)  
Replace if not within 10% of manufacturer's  
rating. Replace if shorted, open, or damaged.  
Will not rotate  
Fan blade hitting shroud or blower wheel hitting  
scroll. Realign assembly.  
Units using slinger ring condenser fans must  
have 1/4 to 5/16 inch clearance to the base. If it is  
hitting the base, shim up the bottom of the fan  
motor with mounting screw(s).  
Check fan motor bearings; if motor shaft will not  
rotate, replace the motor.  
Fan motor runs  
intermittently  
Revolves on overload.  
Check voltage. See limits on page 27. If not within  
limits, call an electrician.  
Test capacitor.  
Check bearings. Does the fan blade rotate freely?  
If not, replace fan motor.  
Pay attention to any change from high speed to  
low speed. If the speed does not change, replace  
the motor.  
Fan motor noise.  
Grommets  
Fan  
Check grommets; if worn or missing, replace them.  
If cracked, out of balance, or partially missing,  
replace it.  
Turbo fan  
If cracked, out of balance, or partially missing,  
replace it.  
Loose set screw  
Worn bearings  
Tighten it.  
If knocking sounds continue when running or  
loose, replace the motor. If the motor hums or  
noise appears to be internal while running,  
replace motor.  
22—  
COMPLAINT  
CAUSE  
REMEDY  
Compressor will not run,  
but fan motor runs.  
Voltage  
Wiring  
Check voltage. See the limits on the preceding.  
page. If not within limits, call an electrician.  
Check the wire connections, if loose, repair or  
replace the terminal. If wires are off, refer to wiring  
diagram for identification, and replace. Check wire  
locations. If not per wiring diagram, correct.  
Rotary  
Check for continuity, refer to the wiring diagram  
for terminal identification. Replace the switch if  
circuit is open.  
Thermostat  
Check the position of knob If not at the coldest  
setting, advance the knob to this setting and  
restart unit.  
Check continuity of the thermostat. Replace  
thermostat if circuit is open.  
Capacitor (Discharge  
capacitor before  
servicing.)  
Check the capacitor.  
Replace if not within 10% of manufacturers  
rating. Replace if shorted, open, or damaged.  
Check the compressor for open circuit or  
ground. If open or grounded, replace the  
compressor.  
Compressor  
Overload  
Check the compressor overload, if externally  
mounted. Replace if open. (If the compressor  
temperature is high, remove the overload, cool it,  
and retest.)  
ROOM AIR CONDITIONER VOLTAGE LIMITS  
NAME PLATE RATING  
MINIMUM  
MAXIMUM  
126.5V  
253V  
115V  
103.5V  
187V  
208/230V  
23—  
REMEDY  
COMPLAINT  
CAUSE  
Compressor cycles  
on overload.  
Voltage  
Check the voltage. See the limits on the preced-  
ing page. If not within limits, call an electrician.  
Overload  
Check overload, if externally mounted.  
Replace if open. (If the compressor temperature  
is high, remove the overload, cool, and retest.)  
Fan motor  
If not running, determine the cause. Replace if  
required.  
Condenser air flow  
restriction  
Remove the cabinet. inspect the interior surface  
of the condenser; if restricted, clean carefully  
with a vacuum cleaner (do not damage fins) or  
brush. Clean the interior base before  
reassembling.  
Condenser fins  
(damaged)  
If condenser fins are closed over a large area  
on the coil surface, head pressures will increase,  
causing the compressor to cycle. Straighten the  
fins or replace the coil.  
Capacitor  
Test capacitor.  
Wiring  
Refrigerating system  
Air filter  
Check the terminals. If loose, repair or replace.  
Check the system for a restriction.  
If restricted, clean of replace.  
Insufficient cooling or  
heating  
Exhaust damper door  
Unit undersized  
Close if open.  
Determine if the unit is properly sized for the area to  
be cooled.  
Excessive noise.  
Blower or fan  
Copper tubing  
Check the set screw or clamp. If loose or missing,  
correct. If the blower or fan is hitting air guide,  
rearrange the air handling parts.  
Remove the cabinet and carefully rearrange tubing  
not to contact cabinet, compressor, shroud, and  
barrier.  
24—  
5. SCHEMATIC DIAGRAM  
5.1 CIRCUIT DIAGRAM  
MODEL : BG-103A  
25—  
6. EXPLODED VIEW  
• MODEL: BG-103A  
132100  
E
152302  
147581  
147582A  
135303  
147582B  
131400  
149980  
135312  
346811  
359012  
W48602  
354210  
559011  
435300A  
435300  
349480  
352380  
554031  
349600  
731273  
130410  
A
264110  
268711B  
249950  
B
567480  
552102  
C
C
352115  
567502  
268711A  
35211A  
C
o
o
l
E
S
n
a
e
r
e
g
r
y
v
F
a
n
F
2
1
L
F
O
W
M
F
E
IG  
554160  
550140  
3
D
H
H
T
i
m
e
'
F
r
M
O
D
E
T
E
M
P
W0CZZ  
T
I
M
E
R
F
E
A
S
N
P
E
D
P
O
W
E
R
352113  
552113  
238310 237200  
267110  
—26—  
7. REPLACEMENT PARTS LIST  
MODEL: BG-103A  
LOCATION  
PART NO.  
DESCRIPTION  
QTY  
REMARK  
NO  
.
130410  
131400  
135303  
135312  
147581  
147582A  
147582B  
149980  
237200  
238310  
249950  
263230  
264110  
267110  
268711A  
268711B  
346811  
349480  
352113  
352115  
35211A  
352380  
354210  
359012  
435300A  
552113  
550140  
552102  
554031  
554160  
559011  
567502  
731273  
WOCZZ  
W48602  
435300  
152302  
132100  
349600  
3041A10064C  
3090A20017D  
3530A10272A  
3531A18004D  
4758A20058A  
4758A30045A  
4758A30045B  
4998A20003A  
3720A20251A  
3831A10037F  
4995A20493V  
6323A20004S  
6411A20048J  
6711A20093A  
6871A20448A  
6871A01001B  
4681A20041J  
4948A20045A  
5211A21421A  
5211A29024A  
5211A21420A  
5238A20033A  
5421A20071G  
5900A20009A  
3530A30015A  
5211A20560H  
4H00982E  
BASE ASSEMBLY,SINGLE  
CABINET  
1
1
1
1
1
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
EA  
GRILLE,INLET  
GRILLE ASSEMBLY,FRONT  
LOUVER,HORIZONTAL  
LOUVER,VERTICAL  
LOUVER,VERTICAL  
SHROUD  
PANEL,CONTROL  
ESCUTCHEON  
CASE ASSEMBLY,CONTROL  
THERMISTOR ASSEMBLY  
POWER CORD ASSEMBLY  
REMOTE CONTROLLER ASSEMBLY  
PCB ASSEMBLY,DISPLAY  
PCB ASSEMBLY,MAIN  
MOTOR,AC  
ORIFICE  
TUBE ASSEMBLY,DISCHARGE  
TUBE ASSEMBLY,EVAPORATOR(IN)  
TUBE ASSEMBLY,SUCTION  
GUIDE,AIR  
EVAPORATOR ASSEMBLY,FIRST  
FAN,TURBO  
GRILLE,REAR  
TUBE ASSEMBLY,CONDENSER(OUT)  
DAMPER,COMPRESSOR  
TUBE,CAPILLARY BENDING  
CONDENSER ASSEMBLY,BENDING  
COMPRESSOR SET,CHINA  
FAN ASSEMBLY,AXIAL  
OVERLOAD PROTECT  
INSTALL PART ASSEMBLY,SINGLE  
CAPACITOR,DRAWING  
CLAMP,SPRING  
5210A23523A  
5403A20183H  
2520UCDK020  
5900AR1173A  
6750U-L058A  
3127A20017C  
6120AR2194D  
3H02932B  
3530A20101A  
5230A20041A  
3210A20075A  
4960A20008A  
GRILLE,REAR  
FILTER,AIR  
FRAME  
BRACKET,MOTOR  
—27—  
Specifications and performance data subject to change without notice.  
HEAT CONTROLLER, INC.  
1900 WELLWORTH AVENUE • JACKSON, MICHIGAN 49203  
THE QUALITY LEADER IN CONDITIONING AIR  
P/No.:3828A20294W  
Printed in Korea  

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